Gallery: New Distillery: Hillrock Estate in Ancram, NY

Truly Local Barley

Hillrock differs from many other distilleries in that it grows its own grain. Pictured here: Australian sheepdog Storm in the barley fields.

Amber Waves of...Rye

The rye fields sit on one side of the distillery, while the barley's on the other.

The Malt House

Once the barley's picked and cleaned, it sits in Hillrock well water for two days. This room is 58 degrees, the perfect temperature for cultivating germination. Distiller Tim Welly, on right, rakes the barley every six hours so it doesn't clump. After 2 to 3 days, the grain has an ideal 45% moisture content and it's time for the next step...

The Kiln

The kiln dries and smokes the grain for 2 to 3 days until it's perfectly crunchy. The final moisture level of the malted barley is 4% or lower.

The Stills

The Mash Bin

Because they make a single malt and a bourbon, Dave designed the mash bin with a dual purpose cooker. For the traditional single malt, they leave in the floor grate for the two washes before fermentation. Then, they shovel the grain out and donate it to a horse farm.

For the bourbon, since the corn would get wedged in the floor and prevent draining, the floor is removed. After the mash, the liquid goes on to fermentation.

Fermentation

There are five fermentation tanks that are also very customizable. A valve on the back of the tanks allows for precise temperature control. The ideal temperature for rye, for example, is 90 degrees.

Further Fermentation

Fermentation goes on for 3 to 5 days. On the left, we have a batch after 1 to 2 days, while on the right, we have a batch after 5 days—the cap has sunk and we begin to get a little malolactic fermentation.

The Pot Still

The 250-gallon pot still comes next—the spirit's in here for about six hours. Valves on the back allow for fine-tuned control.

The Heart

Here's where the head, the heart (middle triangle), and the tails separate. The heart is the part we want to drink, and it comes off the still after the head and before the tails.

The Product Line

Hillrock's first two products for sale will be the single malt and the Solera aged bourbon. They have two more bottlings in the works: a 100% rye whiskey and a high percent rye bourbon.

The House

Baker's house looks down on the distillery complex. In the 1800s, it was home to Captain Israel Harris, a revolutionary war captain and grain merchant.